• 4 Stroke Husqvarna Motorcycles Made In Italy - About 1989 to 2014
     TE = 4st Enduro & TC = 4st Cross

  • Hi everyone,

    As you all know, Coffee (Dean) passed away a couple of years ago. I am Dean's ex-wife's husband and happen to have spent my career in tech. Over the years, I occasionally helped Dean with various tech issues.

    When he passed, I worked with his kids to gather the necessary credentials to keep this site running. Since then (and for however long they worked with Coffee), Woodschick and Dirtdame have been maintaining the site and covering the costs. Without their hard work and financial support, CafeHusky would have been lost.

    Over the past couple of weeks, I’ve been working to migrate the site to a free cloud compute instance so that Woodschick and Dirtdame no longer have to fund it. At the same time, I’ve updated the site to a current version of XenForo (the discussion software it runs on). The previous version was outdated and no longer supported.

    Unfortunately, the new software version doesn’t support importing the old site’s styles, so for now, you’ll see the XenForo default style. This may change over time.

    Coffee didn’t document the work he did on the site, so I’ve been digging through the old setup to understand how everything was running. There may still be things I’ve missed. One known issue is that email functionality is not yet working on the new site, but I hope to resolve this over time.

    Thanks for your patience and support!

TE 250/310 xlite starter issues...

No problem. I'd get a definitive answer from Semco (he's on this forum so he may answer here as well), but they're all Mikuni, so I wouldn't see why not.
 
Spoke with the dealer today and they feel it's the starter on my bike. Now lets just hope that they will cover it under warranty. When the bike failed it was under warranty but by I was a just about 1000 miles from the dealer. By the time I got the bike to them it was out of warranty. Anyone have any experience with husky warranties?
 
RailwayRog said:
That's it, Thanx Phoenix. No wonder my search turned up nothing, it's under the 250 title.
I just had another weird thing happen today, the kick starter stayed engaged to the E start (E-start motor would spin when kicking it over), had to pull the flywheel off with the ring gear stuck to it, used some beveled chisels to tap in between to separate pieces (something I not fond of doing) and man it was stuck on good and that was just from kicking it over lightly, this bike is possessed!
Click to expand...
Is there any chance that stuck flywheel gear kept your bike from starting? I think mine is possessed too:)
 
I spoke with my dealer again today. They are installing a new starter, a new flywheel, and a new reduction gear. I hope this fixes it.
 
What were your symptoms? My freewheel gear is stuck to the flywheel and I can not make it run. Cranks fine but won't start.
 
So after talking with the dealer I am not exactly sure that Husky really know's what is wrong with these bike's either. They are going to warranty every part in the starting drive train except the battery. They are going to replace the starter, worm gear, flywheel, reduction gear, and a few other things I don't remember off the top of my head. Dealer say's it's about $700 in parts all total. I am very great full they are covering it but disappointed they aren't cover labor or the battery. Not sure that the reasoning is but I am not complaining since technically the bike is no longer under warranty but it was when this all happened. What is scary is that it sound like they are tossing the kitchen sink at fixing the problem instead of actually figure out what is going on.
 
wilbur said:
What were your symptoms? My freewheel gear is stuck to the flywheel and I can not make it run. Cranks fine but won't start.
Click to expand...
I think I know what your talking about, the ring gear is stuck to the the flywheel? I had that happen and it was pain prying the two apart and when it was stuck together the e-start motor would not disengage from the crank, I would not want this to happen on the trail cause you can't ride like this and you can't repair this problem on the trail either.

Hey Tessier glad to hear Husky doing something.I've got my new shims to put in this weekend, keeping my fingers crossed.
Still waiting for a reply from Husky.
 
RailwayRog said:
I think I know what your talking about, the ring gear is stuck to the the flywheel? I had that happen and it was pain prying the two apart and when it was stuck together the e-start motor would not disengage from the crank, I would not want this to happen on the trail cause you can't ride like this and you can't repair this problem on the trail either.

Hey Tessier glad to hear Husky doing something.I've got my new shims to put in this weekend, keeping my fingers crossed.
Still waiting for a reply from Husky.
Click to expand...
So what causes these things to get stuck together? Railway, did you reassemble with the parts?
 
Phoenix said:
So what causes these things to get stuck together? Railway, did you reassemble with the parts?
Click to expand...
I examined the two parts (nothing looked out of place) and can not figure out what cause the ring gear to get stuck to the flywheel, without knowing what cause this I'm worried this will happen again out on the trail and I'll be stuck.
And like I said earlier I had to use a lot of force to separate the pieces.
 
Craigl said:
Try setting that left exhaust valve clearance to .005 and see if it starts better before spending any money.
Click to expand...

I just changed out the shim on the ADC side to get .005 valve clearance and it doesn't turn over any better so It looks like I got to replace the starter.
Does anybody know if there are after market starters available for the x-lite? If not I'm stuck buying an overpriced Husky one.
 
RailwayRog said:
I examined the two parts (nothing looked out of place) and can not figure out what cause the ring gear to get stuck to the flywheel, without knowing what cause this I'm worried this will happen again out on the trail and I'll be stuck.
And like I said earlier I had to use a lot of force to separate the pieces.
Click to expand...
I freed mine by using a brass punch and a hammer to spin the gear backwards. It's a 2 person job unless you make a jig to hold the flywheel(I held it on the bench while my father gave it a few wacks). Mine had some fine metal flakes in the clutch mechanism, dad says it doesn't take much to jamb that style clutch. Gonna clean and oil it and see what happens.
 
Does anybody know if there are after market starters available for the x-lite? If not I'm stuck buying an overpriced Husky one.
Click to expand...

I looked around when mine went south and couldn't find one. I was going to send my crapped out one to Stockers Starters to see if they could come up with something, but I guess I never actually did it.
 
wilbur said:
I freed mine by using a brass punch and a hammer to spin the gear backwards. It's a 2 person job unless you make a jig to hold the flywheel(I held it on the bench while my father gave it a few wacks). Mine had some fine metal flakes in the clutch mechanism, dad says it doesn't take much to jamb that style clutch. Gonna clean and oil it and see what happens.
Click to expand...

Dad is correct. This is a simple sprag clutch with oblong rollers under tension by a little spring...any bit of whatever can cock it and lock it.

Make sure the spring that holds it together is not cocked or otherwise damaged. I may have a spare in my parts box.
 
R_Little said:
Dad is correct. This is a simple sprag clutch with oblong rollers under tension by a little spring...any bit of whatever can cock it and lock it.

Make sure the spring that holds it together is not cocked or otherwise damaged. I may have a spare in my parts box.
Click to expand...
Everything looked fine, I cleaned it nice, oiled it up good and put it back together. And...upon closer inspection I discovered a cracked flywheel key.
 
wilbur said:
Everything looked fine, I cleaned it nice, oiled it up good and put it back together. And...upon closer inspection I discovered a cracked flywheel key.
Click to expand...

You bet baby! More than likely the flywheel cocked a touch on the crank and locked the sprag up.

Both x-light motors I took apart had a sheared or a shearing flywheel key. The old motors have the starter clutch splined to the crank for no worries but the x-lights have a ring gear and sprag on the back of a 2-stroke sized flywheel. These motors have 12/1 compression and that's a lot for a small morse taper and woodruff key.

On my bike I took a new flywheel lapped it to the crank just a touch with valve compound and checked it with Prussian Blue to make sure it was mating good then put a little loctite retaining compund on it and torqued it to spec. I will need heat to break it loose but it has been a couple hundred miles and the starter is working perfectly......so far.
 
It has been 4 or 5 times a motorcycle mechanic and no one I solved the problem even in representative HUSQVARNA ...
my engine does not work only hot start, but not yet checked the part of the tree of can and decompressor, if not that I do not know what else to do
 
OK, when you say a sheared flywheel key, what exactly do you mean? Is it broken? Is the top lopped off? Is it rounded off?
 
General question.

Are you able to start these with the kickstart?

If so, I've been told the ADC spring is the issue. .... not that there couldn't be other issues from working against so much compression.
 
You must log in or register to reply here.
Back
Top